Process for production of hydrogen using nonthermal plasma

ABSTRACT

A process for the production of hydrogen, which includes subjecting a hydrogen-containing compound (with the exception of a nitrogen-containing compound) to a decomposition reaction with nonthermal plasma.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates to a process for the production of hydrogen wherein hydrogen-containing compounds such as hydrocarbons, alcohols, and water are efficiently decomposed to produce hydrogen in a good yield.

[0003] 2. Description of the Prior Art

[0004] Hydrogen is a clean fuel and its use is now being watched with a bright prospect as fuel for automobiles and as energy source for other appliances in civil life.

[0005] From the past, a variety of research and development have been made for the production of hydrogen. For example, widely known is a process wherein a hydrocarbon or alcohol is used as starting material and decomposed in the presence of a catalyst such as nickel carried on a support at 300˜800° C. under 1˜30 atmospheric pressure (a reforming reaction of hydrocarbons with steam). In this process, however, some problems arise in an indispensable use of a catalyst and a severe condition of high temperature and pressure.

[0006] Also known is a process for producing hydrogen wherein water is used as staring material and decomposed by way of electrolysis, photocatalysis, mechano-catalysis, etc. to produce hydrogen. However, a research on this process was made only in a closed circulation system. What is worse, these processes involve a problem; the process is compelled to use sacrificial reagents for obtaining hydrogen in a high yield.

[0007] In case hydrogen is produced by continuous decomposition of the aforesaid substances in a flow system, it certainly contributes to the resolution of environmental problems and may be considered to contribute to effective utilization of hydrogen-containing sources. Up to the present, however, a satisfactory process for producing hydrogen has not yet been established on commercial base.

[0008] For solving such problems, the present inventors previously proposed a process for recovering hydrogen, which comprises decomposing an aliphatic amine by nonthermal plasma (JP-A-2000-95501 (“JP-A” means unexamined published Japanese patent application) Japanese Patent No. 2,934,861).

[0009] In the case of using a starting material other than an aliphatic amine, however, the following problems will be presumed: In the decomposition of water, a problem will essentially arise that, because of oxygen molecules formed as a byproduct, water is regenerated by the reverse reaction. (Since hydrogen is consumed in the reverse reaction, the reaction efficiency will be decreased.) In the decomposition of an oxygen-containing compound such as methanol, there may be the case wherein a reverse reaction with hydrogen deteriorates the efficiency of the decomposition reaction, though oxygen molecules may not be formed. In the case of generating hydrogen from a hydrocarbon such as methane, an inhibition of the reaction due to carbon deposits will be expected.

DISCLOSURE OF THE INVENTION

[0010] 1. Problems to be Solved by the Invention:

[0011] The present invention contemplates to develop the invention of the above Japanese Patent 2,934,861 significantly and aims to provide a process for continuously producing hydrogen in a high yield at a high selectivity wherein a hydrogen-containing compound (with the exception of a nitrogen-containing compound) is decomposed efficiently under a mild condition.

[0012] Accordingly, it is an object of the present invention to provide a process for producing hydrogen from a hydrogen-containing compound (with the exception of a nitrogen-containing compound) by way of nonthermal plasma.

[0013] It is another object of the present invention to provide a process for continuously producing hydrogen from a hydrogen-containing compound optionally in the presence of an inert gas by way of nonthermal plasma.

[0014] 2. Means for Solving the Problem:

[0015] As a result of extensive research on a process for producing hydrogen by way of nonthermal plasma, it has been found by the present inventors that in addition to a nitrogen-containing compound such as an aliphatic amine, a nitrogen-free compound including a hydrocarbon such as methane, an alcohol such as methanol, and water is decomposed continuously under nonthermal plasma to produce hydrogen stably at a high selectivity and in a high yield. The present invention has been accomplished on the basis of the above finding.

SUMMARY OF THE INVENTION

[0016] In accordance with an embodiment of the present invention, there is provided a process for producing hydrogen wherein a hydrogen-containing compound (with the exception of a nitrogen-containing compound) is decomposed by way of nonthermal plasma.

[0017] In accordance with another embodiment of the present invention, there is provided the aforesaid process wherein the hydrogen-containing compound is at least one compound selected from the group consisting of a hydrocarbon, an alcohol, and water.

[0018] In accordance with still another embodiment of the present invention, there is provided the aforesaid process wherein the decomposition reaction is carried out in the atmosphere of an inert gas.

[0019] In accordance with further embodiment of the present invention, there is provided the aforesaid process wherein the decomposition reaction is carried out continuously.

[0020] Other and further objects, features, and advantages of the invention will appear more fully from the following description, taken in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0021]FIG. 1 is a flow chart showing a typical continuous process for carrying out the present invention.

[0022]FIG. 2 is a graph showing the effect of a flow velocity of a gas affecting the yield of hydrogen from water in relation to specific energy density (SED; Plug-in power (kW)/Gas flow rate (L/s)) in Example 1.

[0023]FIG. 3 is a graph showing the effect of a flow velocity of a gas affecting the hydrogen yield from methane in relation to SED in Example 2.

[0024]FIG. 4 is a graph showing the effect of a flow velocity of a gas affecting the yield of hydrogen from methanol in relation to SED in Example 3.

DETAILED DESCRIPTION OF THE INVENTION

[0025] 1. Mode for Carrying out the Invention:

[0026] In the present invention, a hydrogen-containing compound (with the exception of a nitrogen-containing compound) is used as a starting material for production of hydrogen. Examples of the hydrogen-containing compound include organic compounds such as hydrocarbons, alcohols, aldehydes, ethers, and esters; and inorganic compounds such as water, hydrogen sulfide, and hydrides. These compounds may be used singly or as a mixture of at least two.

[0027] Any of the hydrocarbons can be used so far as they are volatile. Mentioned as such hydrocarbons are saturated aliphatic hydrocarbons and unsaturated aliphatic hydrocarbons. The saturated aliphatic hydrocarbons are preferably those having 1 to 8 carbon atoms, and more preferably those having 1 to 5 carbon atoms. Examples of the saturated aliphatic hydrocarbons include methane, ethane, propane and 2,2-dimethylpropane, which is higher in hydrogen content per molecule and thus effective. The unsaturated aliphatic hydrocarbons are preferably those having 2 to 6 carbon atoms, and more preferably those having 2 to 4 carbon atoms. Examples of the unsaturated aliphatic hydrocarbons include ethylene, propylene, butylenes, butadiene and the like. The hydrocarbons preferably used in the present invention are methane, ethane, and propane.

[0028] Mentioned as the alcohols are saturated alcohols and unsaturated alcohols. The saturated alcohols are preferably those having 1 to 3 carbon atoms, and more preferably those having 1 to 2 carbon atoms. Illustrative of the saturated alcohols are, for example, methanol, ethanol, propanol, butanol, and ethylene glycol. The unsaturated alcohols are preferably those having 2 to 4 carbon atoms, and more preferably those having 2 carbon atoms. Mentioned as the unsaturated alcohols are allyl alcohol and the like. The alcohols preferably used in the present invention are methanol, ethanol, propanol and butanol.

[0029] In addition to the aforesaid hydrocarbons and alcohols, organic compounds such as aldehydes, ethers, and esters can be employed as the organic compounds. The aldehydes are preferably those having 2 to 4 carbon atoms, and more preferably those having 2 to 3 carbon atoms. The ethers are preferably those having 2 to 4 carbon atoms, and more preferably those having 2 to 3 carbon atoms. The esters are preferably those having 3 to 5 carbon atoms, and more preferably those having 3 to 4 carbon atoms.

[0030] Besides pure water, rainwater, tap water and exhaust water subjected to a primary treatment are used as the water.

[0031] In the present invention, sulfur compounds such as hydrogen sulfide, silanes such as SiH₄ and phosphines such as PH₃, in addition to the water can also be used as the inorganic compounds.

[0032] The above decomposition reaction in the process of the present invention is carried out by using nonthermal plasma. The term “nonthermal plasma” referred to in the present invention means plasma wherein electrons, ions and neutral molecules are not in a thermal equilibrium. An apparatus for such nonthermal plasma has such an advantage that a gas temperature can be suppressed to approximately room temperature although electron temperature reaches 8,000˜40,000° C.

[0033] Any of the known conventional nonthermal plasma reaction apparatus can be used for the present invention and no special limitation exists in this respect. Such nonthermal plasma apparatus includes, for example, a pulsed corona type, a silent discharge type, a packed-bed type or the like.

[0034] A ferroelectric substance-packed nonthermal plasma apparatus wherein electron temperature in the reactor can be maintained especially at a high temperature is effective for the present invention. The electron temperature is preferably within the range of 30,000˜40,000° C. A dielectric constant of the ferroelectric substance may be selected at need, but the constant is usually 1,000˜15,000, preferably 3,000˜10,000 at room temperature. A loading voltage is usually 3.0˜10.0 kV, preferably 5.0˜8.0 kV since an excessively high voltage makes conductivity in the reactor higher so that the so-called breakdown phenomenon takes place to make it impossible to initiate microdischarge in the reactor.

[0035] The decomposition reaction in the process of the present invention can be carried out generally within a temperature range from room temperature to about 200° C., and preferably within a temperature range from room temperature to about 100° C., whereby a concentration of the decomposition substance may be adjusted depending on its vapor pressure. In case of the reaction at around room temperature, increase in temperature in the course of the decomposition reaction is usually about 1˜2° C.

[0036] In the present invention, the aforesaid starting material may directly be introduced into a nonthermal plasma reaction apparatus to effect the decomposition reaction but it is preferred to use an inert gas (for example, gaseous nitrogen, argon or the like) as a background gas during the reaction.

[0037] In case the background gas is used, it is preferable that an oxygen concentration in the gas is decreased down to 1% or less. If the oxygen concentration in the background gas exceeds 1%, hydrogen formed by the decomposition reaction may be converted into water to reduce a recovering ratio of the hydrogen gas.

[0038] In order to carry our the decomposition reaction of the present invention, the aforesaid starting material to be treated is preferably mixed with the background gas previously to form a reaction gas, which is then introduced into the nonthermal plasma reactor.

[0039] The yield of hydrogen is considerably influenced by the concentration of the reaction gas and a flow velocity of the gas. In order to optimize the amount of hydrogen formed per unit time, it is desirable to increase the concentration of the substance to be treated and the flow velocity of the gas. In usual cases, the starting compound is mixed with the background gas so that the concentration may become at least 0.5%, preferably at least 2˜3%. No special limitation exists in reaction pressure, but it is preferably low pressure up to about several atm. pressure, and more preferably atmospheric pressure (1 atm. pressure).

[0040] The use of a catalyst is not indispensable in the present invention. However, the catalyst may be used if necessary. Examples of utilizable catalyst include a noble metal such as gold and platinum and a metal oxide such as silica, alumina, silica-alumina, etc.

[0041] In the present invention, it is preferable that a substance capable of eliminating oxygen formed as a byproduct by the decomposition reaction, such as a deoxygenating agent, for example, alumina is previously added to the reaction system.

[0042] The reaction of the present invention for producing hydrogen by way of nonthermal plasma may be carried out either batchwise or continuously. In the present invention, however, a continuous process is preferably adopted since, in the present invention, even if the reaction gas is continuously fed to the reactor, the decomposition reaction by nonthermal plasma can be carried out stably and the yield of hydrogen is not so much decreased.

[0043]FIG. 1 is a flow chart illustrating a typical continuous process of the present invention for producing hydrogen with nonthermal plasma. In FIG. 1, 1 denote a feed gas, 2 denote a background gas, 3 denote a control system for gas flow rate, 4 denote an evaporating system for the feed gas, 5 denote a nonthermal plasma apparatus for producing hydrogen, 6 denote a system for analysis, and 7 denote an apparatus for separation and recovery of hydrogen.

[0044] Below is an explanation on the process of the present invention using the apparatus shown in FIG. 1.

[0045] A feed gas 1 is preferably mixed with a background gas 2 and a mixed gas is introduced into a control system for gas flow rate 3 through a stop valve, a flow control valve (not shown), and the like. The mixed gas consisting of the feed gas and the background gas is then introduced into the nonthermal plasma apparatus for producing hydrogen 5 where the decomposition reaction is carried out to produce a gas containing hydrogen. The resultant gas containing hydrogen is analyzed by the system for analysis 6 such as a gas chromatographic apparatus where a gas composition of the reacted gas is determined. The gas thus treated is conveyed to the apparatus for separation and recovery of hydrogen 7 where the produced hydrogen is isolated and recovered. A waste gas other than hydrogen is finally treated in a waste gas treatment system (not shown). The evaporating system 4 is used in the event the feed gas is a liquid, for example, water or an alcohol.

[0046] Examples of the continuous type reaction apparatus used in the present invention include a reaction apparatus of a pulsed corona type, a silent discharge type and a packed-bed type. Among them, a reaction apparatus of a packed-bed type is preferably used.

[0047] In the process of the present invention for producing hydrogen by way of nonthermal plasma, for example, CO and hydrocarbons besides hydrogen are obtained from the starting hydrocarbons while a trace amount of hydrocarbons and CO besides hydrogen are obtained from the starting alcohol.

[0048] In the case of using a ferroelectric packed-bed type nonthermal plasma apparatus, such a phenomenon was observed that a molar ratio of the formed H₂ to O₂ was more excessive in H₂ than the stoichiometric ratio. It is assumed that the generated oxygen atoms are migrated from the surface of a ferroelectric material such as BaTiO₃ into lattice oxygen.

EXAMPLES

[0049] The present invention will now be illustrated in more detail by way of Examples.

Examples 1˜3

[0050] In accordance with the flow chart as shown in FIG. 1, water (Example 1), methane (Example 2) and methanol (Example 3) were treated by way of nonthermal plasma.

[0051] More precisely, decomposition reactions of water (Example 1), methane (Example 2) or methanol (Example 3) were carried out using a packed-bed type nonthermal plasma reactor filled with pellets of a ferroelectric substance (a distance between the electrodes: 1.54 cm), which was barium titanate (BaTiO₃) having a particle diameter of 1 mm and a dielectric constant at room temperature of 5,000.

[0052] A 50 Hz alternate current voltage was applied between electrodes and consumed electric power at the primary side was measured by a digital powermeter. SED was then calculated as a ratio of the consumed electric power to the flow velocity of a gas. Dry nitrogen gas was used as a background gas. In the case of the reaction with water or methanol, a reaction gas was prepared by azeotropic evaporation of distilled water or methanol placed in a small washing bottle. The concentration of water was adjusted by using a dew point hygrometer. A reaction gas having 1% concentration of water, methane or methanol was used. The flow velocity of gas was varied within a range from 0.05 liter/min (a gas residence time: 89 seconds) to 1.0 liter/min (4.4 seconds). Identification of byproducts having relatively high molecular weights was carried out using GC-MS (Shimazu GC-MS QP 5050A) provided with a capillary column (DB-1). A quantitative analysis was carried out using a GC (GL Science, GC-353, TC-1) provided with FID (flame ionization detector) for an organic byproduct having a relatively high boiling point, while using GC (Shimazu GC-9A, Porapak Q+N, Molecular Sieve 13X) provided with TCD (a thermal conductivity detector) and FID for hydrocarbons of C₂ or less as well as CO and CO₂. A quantitative analysis of H₂ was carried out using GC (Shimazu GC-14, Porapak Q) provided with TCD. FIG. 1 illustrates a treatment flow according to the present invention.

[0053]FIGS. 2, 3, and 4 are graphs showing a correlation between the yield of hydrogen and SED observed when decomposing water, methane and methanol, respectively. In the decomposition reactions of these compounds, the yield of hydrogen was increased as the value of SED was increased. The maximum yield of hydrogen depended on the chemical structure of a substance to be decomposed, and the values in the case of water, methane, and methanol were 29%, 48% and 88%, respectively. It is recognized that with the same SED values, the yield of hydrogen tended to become higher as the flow velocity of gas became higher. This is due to the reason that as the residence time of gas becomes longer, occurrence of a reverse reaction of the formed oxygen and hydrogen cannot be neglected. In case the value of SED was same, the yield of hydrogen became higher in the case of methanol in comparison of water with methanol. This is probably ascribable to the reason that methanol is more easily decomposed than water and that oxygen gas is not formed as a byproduct.

[0054] In case of producing hydrogen from water, for example, the yield of hydrogen as high as 18.5˜20.4% was maintained for consecutive 10 hours under the conditions that an applied electric voltage was 7.6˜8.0 KV, while a consumed electric power at primary side was 24.3˜25.0 W. This fact apparently shows that the process of the present invention is stably operable continuously for a long period of time.

[0055] Effect of the Invention

[0056] According to the present invention, hydrogen-containing compounds (with the exception of nitrogen-containing compounds) such as hydrocarbons, alcohols and water, which are chemically poor in activity, can efficiently be decomposed under mild conditions to produce hydrogen at a high selectivity and in a high yield.

[0057] It is understood that the preceding representative examples may be varied within the scope of the present specification as to both reactants and reaction conditions, by those skilled in the art to achieve essentially the same results.

[0058] As many widely different embodiments of the present invention may be made without departing from the spirit and scope thereof, it is to be construed that the present invention is not limited to the specific embodiments thereof except as defined in the appended claims. 

What is claimed is:
 1. A process for the production of hydrogen, which comprises subjecting a hydrogen-containing compound (with the exception of a nitrogen-containing compound) to a decomposition reaction with nonthermal plasma.
 2. The process according to claim 1, wherein the hydrogen-containing compound is at least one compound selected from the group consisting of a hydrocarbon, an alcohol and water.
 3. The process according to claim 1, wherein the decomposition reaction is carried out in an atmosphere of an inert gas.
 4. The process according to claim 1, wherein the decomposition reaction is carried out continuously.
 5. The process according to claim 2, wherein the decomposition reaction is carried out continuously.
 6. The process according to claim 1, wherein the hydrogen-containing compound is an organic compound selected from the group consisting of hydrocarbons, alcohols, aldehydes, ethers, and esters, or an inorganic compound selected from the group consisting of water, hydrogen sulfide, and hydrides.
 7. The process according to claim 1, wherein the decomposition reaction is carried out in a temperature range from room temperature to 200° C.
 8. The process according to claim 1, wherein the decomposition reaction is carried out in an electron temperature range of 30,000˜40,000° C. 